Unitary container



Jan. 22, 1957 G. A. MOORE 2,778,557

UNITARY CONTAINER 'Filed May 28, 1952 2 sheets-sheet 1 1N VEN TOR,

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Jan- 22, 1957 G. A. MOORE UNITARY CONTAINER 2 Sheets-Sheet 2 Filed May 28, 1952 INVENTOR.

UNITARY CONTAINER George Arlington Moore, New York, N. Y.

Application May 28, y1952, Serial No. 290,455

Claims. (Cl. 229--16) This invention relates to improvements in hermetically sealed containers made from a single blank of sheet material. The sheet materials for making the containers comprise fibrous sheet, plain, or laminated with other sheet material of fibrous, plastic or metallic composition, the sheet for the blank having surfaces of plastic ilm, such as extruded polyethylene, coatings of Saran or suitable vinyl compositions having thermoplastic properties.

The container of this invention is substantially impervious and adapted to be hermetically sealed making it economically useful for distribution of hygroscopic foodstuffs and other commodities that require protection from elements of the atmosphere.

Conventional containers made of fibrous materials, including folding cartons, have interiorly exposed raw wicking edges of material that is detrimental to the keeping ability of the container, therefore such containers are treated with wax, or they are provided with inner liners of sheet material in which to contain the product, the liners being folded and closed in bag-like form, either separately, or in conjunction with the closure flaps of the container. For further protection of the product the containers are wrapped with various kinds of sheet material, such as waxed paper, cellophane or sheet laminates.

lt is an object of this invention to provide a substantially impervious and hermetically sealed container made from a single blank of sheet material.

Another object of the invention is to provide a container having an interior wall structure free of raw Wicking edges of material.

A further object of this invention is to provide a con rainer having a bottom reinforced with corner folds adapted to hermetically seal the bottom corners.

A still further object of the invention is to provide a container having a filling closure adapted to be permanently closed and a dispensing closure adapted to be opened and closed.

These and other objects of the invention will be apparent upon reading the following descriptive disclosure read in conjunction with the illustrative accompanying drawings, wherein; f

Fig. 1 is a plan view of the blank used to form the container,

Fig. 2 is a fragmentary view of the blank with wall areas .in partially folded position,v

Fig. 3 is a fragmentary view in end elevation of wall areas of the blank in further folded positions,

Fig. 4 is a fragmentary View in end elevation of the folds completed,

Fig. 5 is a fragmentary view in cross-section taken on line 5 5 in Fig. 4, with fragmentary members of container forming and sealing toolsin cross-section,

Fig. 6 is a perspective view of the formed container,

Fig. 7 is a longitudinal view in cross-section taken on line 7-7 in Fig. 6, A

Fig. 8 is an enlarged fragmentary view in cross-section 2,778,557 Patented Jan. 22, 1957 of a portion of the closure shown at the top of Fig. 7, and

Fig. 9 is a perspective View of the container with dispensing closure in open position.

The container 42 (Fig. 6) of this invention may be fabricated from a fibrous sheet having suitable thermoplastic film on its surface. To avoid having exposures of raw wicking edges of material Within the interior wall structure of the container, this invention provides means to imbricate the edges of the material exteriorly of the interior walls of the container.

1Referring more particularly to Fig. 1, a longitudinal blank 43, consisting of fibrous sheet material of suitable gauge, for example, 0.010 to 0.020 inch thickness, is provided with an extruded film of polyethylene, or a coating-of Saran, vinyl resinous compositions or other suitable lms having thermoplastic properties.

The blank 43 has a central bottom firming panel area 44 and is defined by longitudinal parallel fold lines 45, which lines extend longitudinally relative to the blank and transversely disposed parallel fold lines 46, which lines 46 terminate outwardly of the lines 45. Lateral wall areas 47, extend, left and right, outwardly of each junction line 46. The left wall area 47 has an end panel 43, the right wall area 47- has an end panel 49, each panel having fold lines 50 and 51 respectively. The lines 50 and 51 are parallel to each other and transverse of parallel fold lines 45. Opposed wall areas 52 are disposed outwardly of the central wall area 44 by defining fold lines 46a with outwardly extended cut lines 53. Folding lines 56 extend transversely across the areas 52 inwardly of the end edges 56. The left lateral panel area 47 is provided with opposed longitudinal side wall panel areas 57 and 58 which terminate on outer ends with foldable marginal portions 59 and 60. Marginal wall area 59 is bounded by lines 61 and 62, a portion of cut line 4S and opposed blank edges 57a and 58a, whereas marginal wall area 60 is bounded by edges 60a, part of cut line 48', and opposed blank edges 57a and 58a. The line 61 is disposed inwardly of the line 50. The area 58 is provided with a tongue 63 outlined by perforated line 63a. The right lateral panel area 47 is provided with opposed longitudinal side Wall panel areas 64 and 65 which have tab end margins 66 defined by fold lines 67, cut lines 49', edges 66a, and portions of edges 64a and 65a. The lines 67 are disposed inwardly of the fold line 51. The wall area 65 is provided with a pair of parallel perforated cut lines 68 and semi-circular cut lines-69 defining semi-circular areas 69. A crescent shape aperture 70 is disposed inwardly from the junction line 67, the curved line 71a forming the edge of a tab 7l disposed between the cut lines 69a.

The side wall areas 57, 58, 64 and 65 are provided with triangular wall portions 55 being defined by cut lines 54, and fold lines 46a and 54a. The lines 46a being extensions of lines 46. Lines 54 are parallel to folding lines 56. Lines 54a are about 45 degrees with respect to lines 46a and terminate at corners of the central area 44.

The enclosure walls of the container are formed from blank 43 by being folded upon a mandrel 72 (Fig. 5). Each of the wall portions 52 (Fig. 2) is provided with an upper margin which is folded outwardly and downwardly to dispose said margin in selfesuperimposed relationship and thereby bring the corner edges 56 in line with the cut edges 54 of the triangular pleated folds 55. Thus a smooth wall area 52 (Fig. 7) with looped edges 56a is disposed within the interior of the container. The wing-like pleated folds 55 of the wall areas 57 and 58 are disposed exteriorly of eachv of the inner wall areas 52, the pleated folds 55 of the walls 64 and 65 are disposed exteriorly of the said inner Walls 57 and 58 in the folded container (Fig. 4). The cut edges 53 and the edges 57a and 58a of the walls 57 and 5S are in edge to face abutment with the adjacent right inner wall- 47.

The overlapping end Walls on opposed sides of the container are com'presed and heated with sealing tools (Fig. 5). The sealing tools consist of a pair of irons 75 disposedt on two opposed sides of the mandrel 72. These irons are equipped with suitable electrical heating elements 76 which are connected with electrical current. The faces of the irons 75 and the two opposed faces of the mandrel 72 are machined toco-operate in accommodating the multiple thickness of inwardly disposed wall material as shown in- Fig. 7. The irons '75 have sidelplates 77, which have an independent motion, these plates 77 being in upwardly disposed position when the irons contact the exterior Wall surfaces of the container on the mandrel. Then the side plates 77 move downwardly over the corner sides of the container as full compression on the' material takes place by the heated irons 75; This. cto-action. of the irons andV side platesv unites the overlapping. wallsand tightens the abutments of the above described edge tojface engagements of wall material disposed in the interior of the container. The said edges are int abutmentwith thermoplastic film surfaces which are softened by thefh'eat from thev irons and plates. The edges in abutment are united to the said plastic lm surfaces upon solidification of the plastic film. The mandrel 72 may bel provided' with Teflon plates 78 to avoid injury to the' plastic film on the inner walls of the container. The

pressureof the irons is exerted from two opposed sides of the mandrel producing substantially balanced pressure.

Thel container 42" (Fig. 6') is provided with a dispensing closure formed in. the overlapping walls 58 and 65. The' tab portion. 71. and the area between the perforated lines 63 and 68 are lightly compressed by segments in the facel of one sealing'v iron 75l The crescent shaped aperture 70T in the wall265 is sealed olf from the interior of the container. by the inner wall 58. The recess formed by the sealing' off" ofthe sealed aperture provides access to the tab` 7-1.

The filling endy of thev container is provided with wall areas 48 andi 49 adapted to be folded to form a reinforced atl walled end closure. The opposing end walls of the container. are provided with upper wall areas 59, 6i? and 66i that. fold cosoperatively in double wind-like formation,th'e tab areas 66 being disposed in interlocking relationsh'ip between revers'ely' folded marginal areas 59 and 602 The wall areas 60 are folded outwardly to provide an upper face of thermoplastic film. The folds 59, 60 and 66 are closed flatly to allow the panel area i3 to fold inwardly and dow-nwardl'y'from' the junction line 50, the innerwall of thermoplastic film thereby making contact withy the upturned faces of the wing marginal areas 60 having surfaces'of thermoplastic lm. The panelarea 49 is then folded inwardly and downardly from junction line 51; the inner wall of thermoplastic lm thereby overlapping the exterior wall of the first folded panel 48. The folded wing-like wall areas have a spring-like action and consequentlyoppose the downward pressure of the foldedI overlapping panels 48'? and 49.

When heat and pressure is applied to the exterior wall area 49 (Figs. 7 and 8) of the folded closure, said pressure is resisted-` by the folded and interlocked wing coacting marginal areas 59, 60 and 66, the Wings being strongly supported by the united double walls of the two oppcsingsidesof the container. rfhe interlocked tab area 66l reinforces the other marginal areas of the wing folds, thereby forming inwardly opposed strongl ledges (Figs. 7 and 8)` within the container to support the overlapping panel areasl 48 and 49 and resist the pressure imposed by the sealingirons; The side edges of the folded areas 59, 607and 66, are encased in wall recesses formedv b'y the lines 50 and'51, the longitudinally disposed edge of the first folded panel 48 being encased in the wall recess formed by the fold line 51 as shown in Figure 6. All of the said edges are in abutment with thermoplastic lm. Suitable heat sealingT irons compress and heat the walls of the folded closure thereby activating the intermediate layers of thermoplastic film disposed within the folds of the closure, thereby uniting the folds in the manner of a hermetically sealed closure of the container.

The interior structure of the completed container of this invention is therefore free of all wicking edges of Wall material, which edges if otherwise exposed would wick moisture into and out of the container. Such edges otherwise exposed would also absorb grease or oily substances. rfhe interior walls of my container are substantially impervious to moisture vapor, grease and oleaginous substances in general. The folded material within the walls and adjacent the interior end wall of the container, have looped plastically covered corner edges 56a and 79 (Figs. 7 and 8). All of the other interior edges are in edge to face abutment with co-acting adjacent wall areas having plastic film.

The container i2 (Fig. 9) may be opened by breaking the seal of the dispensing closure. The tab 71 is raised upwardly by being grasped with the ngers thereby severing the tongue 63 and the attached wall area between the parallel perforated lines 68 of wall area 65, thus exposing a dispensing aperture el through the inner wall 58 of the container. This aperture S1 may be repeatedly opened and closed by restoring the tongue 63 into aperture 81, The dispensing closure is retained in closed position by the co-action of the semi-circular edges 82 located in the sides of the tab 7l, thereby producing an anchor effect with the opposing lugs 69, which lugs project inwardly with respect to the container side walls 47. The said anchor effect overcomes theinherent spring in the material thus providing a means to replace the tongue 63 substantially in the aperture 81.

l claim:

l. A container of sheet material comprising side walls folded and being arranged in opposing pairs and having a flat bottom end wall integrally related with said side walls, two of said opposing side walls being of single thickness and being folded upwardly from two parallel corner edges of said bottom wall, the other pair of opposing side walls being of multiple thickness, each multiple wall layer bein-g folded inwardly from a vertical corner edge of saidV single thickness side walls, and being adhesively secured together in overlapping relationship, said bottom wall being provided with two opposed extending wall portions, each of said portions having a pair of opposed triangular defined extensions that project outwardly into each bottom end of each side wall layer of multiple thickness, said extending Wall portions being folded upwardly from two' opposed transverse corner edges of said bottom end wall and an upper marginal portion thereof being folded outwardly and downwardly in a self-superimposed relation to its dependent wall. the opposed vertical corner edges of said folded wall portions being disposed in abutment with interior surface margins of said single thickness side walls, said folded extending wall portions being disposed in the interior of the container andthe folds causing' said triangular wall extensions to fold and form corner closing pleats that co-act with said folded selfsuperimposed margins and thereby seal the lower base' ends of said multiple side walls upwardly adjacent said bottom end wall, said folded portions being adhesively secured together in seam forming relationship.

2. A container as set forth in claim l wherein the horizontal end edge of each said self-superimposed folded margin isdisposed downwardly of its upper folded corner edge and being enclosed between the interior surface of the inner layer of said multiple side walls and exterior of its vertical dependent wall portion.

3. A rectangular container made of a single blank of sheet material treated with a surface coating of activator adhesive comprising a bottom end wall, side walls being folded and arranged in opposing pairs, said bottom wall being provided with outer opposed wall extensions which project into the opposed ends of wall portions that form one pair of said opposing side walls, said wall extensions being folded upwardly and inwardly to lie in vertical position within the interior of the container structure, an upper margin of each folded extension being folded outwardly and downwardly to form a double wall margin, the projected wall portions into said side walls being folded into triangular pleats that close converging corner ends of said bottom end wall, said pleats coacting with said side walls, which side walls are folded in overlapping relationship and along vertical corner edges of an adjacent pair of opposing side walls that are folded upwardly along two opposed corner edges of said bottom wall, the exterior surfaces of said overlapping opposed side walls being pressed with heat to activate said activator adhesive and thereby to effect a bonded union of said folded wall portions of the container structure.

4. A rectangular container as set forth in claim 3 wherein the opposed side edges of said vertically folded extensions of the bottom end wall are disposed in abutment with interior surface margins of an adjacent pair of opposing side walls of the container, vertical corner edges of the inner disposed overlapping pair of side walls being disposed in abutment with interior surface margins of said adjacent pair of opposing side walls, said abutted edges providing means with which to render the interior of the container free of cut edge exposure therein of structural material.

5. A rectangular container being provided with wall surface coating of activator dry adhesive and having side walls arranged in opposing pairs, a closed bottom end and an open top, comprising one pair of opposing side walls being folded upwardly along two opposed corner edges of said bottom end wall, the second pair of opposing side walls each being folded of two panels, each panel of each side wall being alternately folded inwardly in overlapping relation along a vertical corner edge of each wall of said one pair of first folded side walls, said bottom end wall being provided with two opposed end wall extensions that are folded upwardly and inwardly of said overlapping side walls, which folded bottom end wall portions are each reinforced with an opposed pair of upwardly and inwardly folded corner closing pleats that are integrally related with said bottom end wall and the material of the pleats being supplied by the overlapping side walls, said pleats being disposed to co-act with an outwardly and downwardly folded margin of an upper portion of said folded bottom end wall extensions and thereby tightly close the bottom and body structure of the container by said upper folded margins each facing a marginal interior surface portion of the inner wall layer of said overlapping side walls, the horizontal upper edges of said pleats being disposed in line with the downwardly facing horizontal edges of said upper folded margins of the bottom wall folded extensions, the contacting surfaces of said side walls and folded extension portions being adhesively secured together in seam forming relationship by application thereto of heat and pressure which activates said dry adhesive.

6. A container of sheet material having side walls arranged in opposing pairs to provide a rectangular horizontal cross section of the container body, the interior wall surfaces of said container being provided with a film of thermoplastic material, the interior wall enclosure structure of the container being void of raw edge structural material which comprises, a uniformly flat bottom end wall having integral marginal wall portions folded upwardly along two opposed parallel corner edges thereof and two opposed integral side wall portions being folded upwardly along two opposed transverse corner edges, said folded marginal wall portions each having a pair of outwardly opposed triangular shaped wall portions defined with horizontal slit lines disposed in lower end portions of another pair of opposing side walls that are integrally hinged along each vertical corner edge of each said first folded pair of side walls, each of said folded marginal wall portions of the bottom wall being provided with an upper marginal portion of its wall folded outwardly and downwardly in self-superimposed relationship and being disposed in face to face surface contact with the interior surface of each inner wall layer of two layers that are folded to form said other opposing pair of side walls, which side wall layers are folded inwardly along said vertical corner edges of the pair of first folded side walls, said folded bottom wall marginal portions and two layer side walls causing said triangular shaped wall portions to fold into converging corner closing pleats at four corners of said bottom wall, the cut horizontal edges of said pleats and self-superimposed folded margins being disposed in horizontal alignment and between inner and outer surface portions of said folded wall portions of the bottom and side walls, said inner side wall layers each having their respective vertical cut corner edges in abutment with the interior surface of said first folded side walls, the opposed side cut corner edges of said folded bottom wall marginal portions being disposed in abutment with the interior surface of said side walls that are disposed inwardly adjacent 'the first mentioned edge to surface abutments, heat and pressure being applied upon exterior surfaces of said opposed two-ply side walls, thereby activating said film of thermoplastic material, the contacting surfaces of said folded layers of the side wall structure being sealed together in seam forming relation-4 ship, said edge to wall surface abutments rendering the interior wall surfaces of the structure that forms said bottom and body side walls free of exposed raw edges of structural material.

7. The method of making a container having a plurality of side walls arranged to provide a rectangular cross section from a flat paper boardblank having a central rbottom forming panel with two opposed extended short marginal wall portions and including six integral wall panels to provide four side walls to be arranged in opposing pairs, two of said panels being provided with integral end closing full panel portions, and two of the other four walls being provided with integral marginal portions having a central score line, and the balance of two walls of the other four walls being provided with integral end tab portions, the method comprising coating a surface of said blank with thermoplastic material capable of rendering said surface substantially impervious and heat scalable, placing said Vblank in register with a mandrel and folding two side walls upwardly along two opposed parallel corner edges of said central bottom wall portion, folding said two opposed marginal portions of the bottom wall upwardly along two opposed transverse corner edges thereof, folding an upper horizontal marginal portion of each folded bottom wall margin outwardly and downwardly in self-superimposing relation with its dependent folded wall portion, folding in pairs each of the remaining four side wall portions inwardly along each longitudinal corner edge of the rst pair of folded side walls each pair to be positioned in overlapping relationship which cause integral slit wall portions provided in each of these pairs to flatly fold in triangular pleats upwardly of the four converging corner 4ends of the bottom and side walls, bringing the horizontal edges of said pleats into alignment with the horizontal end corner edge of said outwardly and downwardly folded margins of the folded bottom wall portions, the longitudinal end corner edge of each inner disposed side wall portion of the overlapping pair of opposed side walls being presented in abutted engagement upon the plastic face of an interior surface portion of the first folded side walls, heating and pressing each of the pair of overlapping side walls upon opposite sides of said mandrel to activate said coating of thermoplastic material to effect a bonded 7' union of wall surface contacts which includes said overlapping side walls, edge Ito' surface abutments, pleat folds, bottom wall folded extensions and marginal folds thereof all in seam forming relationship.

S. The method according to claim 7 wherein the filled container may be closed by first folding said end marginal and end tab portions of each inner and 'outer wall layer-of said pair of overlapping side walls, folding inwardly at substantially right angles of corresponding walls', folding the inner-most margin of the inwardly folded marginal portions of the inner wall layers and on their respective fold lines upwardly, outwardly and downwardly so 'that the in-folded end tab portion of the outer wall layers will be inserted and interlocked between the lower and upper marginal folds at the top ends of said side walls, presenting the opposite side edges of the three-ply inter-locking folds upon corresponding plastic interior surface portions of the adjacent pair of opposing side walls, folding one of said full panel portions thereof downwardly and flatly upon the flat plastic face the upper disposed ,margin of inter-locking folds, and presenting the longitudinal end edge of the folded full panel upon a corresponding plastic interior surface of the opposing side wall, the face of said edge brought into coplanar surface relationship with the parallel edges of a side of two longitudinally opposed transverse three-ply margins. folding the second of said full panels upon the first folded panel, heating and compressing the folded closure resisted by the spring effects of said three-ply folded margins, the effects of heat and pressure activating said plastic surfaces and bonding the closure in seam formingv relationship, the interior of the container closure structure being void of raw edges of folded material.

9. A rectangular container being provided with wall surface coating `of activator dry adhesive and having side walls arranged in opposing pairs with a closed bottom end, comprising one pair 4of opposing side walls being folded upwardly along two opposed corner edges of the bottom' end wall, the second pair of opposing side walls each being folded of two panels, each panel of each side wall being' alternately folded inwardly in overlapping relation along a vertical corner edge of each wall of said one pair of iii-st folded side walls, said bottom end wall being provided with two opposed end wall extensions that are folded upwardly and inwardly of said overlapping side walls, which folded bottom end wall portions are each reinforced with an opposed pair of upwardly and inwardly folded corner closing pleats that are integrally related with said bottom end wall and the material of the pleats lbeing supplied by the overlapping side walls, said pleats being disposed to co-act with an outwardly and downwardly folded margin of an upper portion of said folded bottom end wall extensions and thereby tightly close the bottom and body structure of the container by said upper folded margins each facing a marginal interior surface portion of the inner wall layer of said overlapping side walls, the horizontal upper edges of said pleats being disposed in line with the downwardly facing' horizontal kedges of said upper folded margins of the bottom wall folded extensions, the contacting surfaces of said side walls and folded extension portions being adhesively secured together in seam forming relationship b y application thereto of heat and pressure which activates said dry adhesive.

10. The method of forming a rectangular shaped container from a single blank of foldable sheet material 8 having a surface of thermoplastic material comprising folding' panel portions of 'said blank to provide four side walls arranged in opposing pairs providing a body por'- tion of tlie container rectangular in horizontal cross section, folding one pair of said side walls upwardly along' two opposed parallel corner edges of an integral wall portion forming Ea bottom end wall of said body portion, folding outwardly opposed longitudinal panel portions of first folded side walls inwardly of longitudinal corner edges thereof to forni in overlapping surface relationship thereby forming the other pair of opposing side walls, folding outwardly opposed short wall portions of said bottom end `wall upwardly along transverse fold lines thereof and placing each of said folded short portions inwardly f the overlapping side wall portions, bottom ends of :l overlapping portions supplying the material that forms two opposing pair of corner closing pleats upwardly from converging corner ends of side walls and bottom end wall, folding an upper marginal portion of cach short 'wall outwardly, downwardly and inwardly in self-superimposing relationship to face a coincident interior surface portion of the inner layer of folded overlapping side walls thereby enclosing the raw end edge of the folded short wall between side wall forming portions adjacent the bottom wall of the container structure,

ringing said enclosed edges of the short folded Wall poil ns into alignment abutting relationship with parallel upper corner edges of the folded pleats, enclosing said pleats between coincident interior surfaces of the overlapping side wall portions, pressing while heating said opposing pair of overlapping side walls including said short wall folded portions and pleats to activate said thermoplastic material on the surfaces thereof to effect a seal of the engaging surfaces in seam forming relationship and, including an effective seal of transversely opposed side edges of the folded short wall portions abutting upon corresponding interior surfaces of the adjacent pair of opposing side Walls whereby, the interior wall surface structure of the body of the container is void of raw exposure of folded material.

References Cited in the tile of this patent UNTTED STATES PATENTS Re. 16,347 Bliss May 11, 1926 831,760 Anderson Sept. 25, 1906 1,591,427 Leary July 6, 1926 1,906,964 Hill May 2, 1933 1,923,089 l-lelt Aug. 22, 1933 l,985,778 Himes Dec. 25, 1934 2,137,614 Hinkle Nov. 22, 1938 2,299,461 Clarion Get. 20, 1942 2,342,551 Levkoil' Feb. 22, 1944 2,357,535 Monroe Sept. 5, 1944 2,417,104 Cope Mar. l1, 1947 2,437,114 Moore Mar. 2, 1948 2,457,822 .Tones lan. 4, 1949 2,524,441 Guyer Oct. 3, 195() 2,549,373 Forsyth Apr. 17, 1951 2,553,804 Zinn May 22, 1951 2,555,581 Dunning lune 5, 1951 2,593,019 Glaser Apr. 15, 1952 2,596,224 Eaton et al. May 13, 1952 FOREIGN PATENTS 537,617 Great Britain June 30, 1941 

